I'll reiterate what I mentioned in the chatbox for you, in case it scrolls away before you see it.
Looking at your diagram, I'm not sure you used the right resistor for your illuminated switch. It appears to be this one:
http://www.thecustomsabershop.com/16...itch-P703.aspx On a 3.3v pad, you'd only want a 68 ohm resistor, not the 270 ohm that you have in your diagram. That LED is going to have a hard time illuminating with that particular resistor in place.
Warm is fine. Hot is not. If it's painful to the touch and makes you snatch your hand away, then you have a real issue. If you can hold it without discomfort, then it should be ok.
Before you start rewiring the entire saber...recharge the batteries. 9/10 times, the issue with odd saber behavior is related to a low charge on your li-ion cells, especially if it was working fine before.
Edit: Now that I've seen your soldering pictures, I'll change my advise. Please rewire that board.
http://www.youtube.com/watch?v=AOdnGUMi7lQ is the tutorial I used when learning to solder. You'll want to practice a bit.
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